Tonneau cover assemblies

ABSTRACT

Elongated side rails for attachment to a sidewall of a truck cargo box as a portion of a tonneau cover assembly. Each assembly includes a flexible cover that can be operatively secured to side rails. One side rail includes a securing portion that can be operatively connected to the sidewall; an inclined portion extending from the securing portion, the inclined portion having first and second sides; a connecting member extending downwardly away from the inclined portion from a position located between the first and second sides; and a longitudinal portion extending from the connecting member opposite the inclined portion. To secure the cover to the side rails, hook fastener is preferably attached to loop fastener on the cover. One preferred side rail has a ridge to prevent premature engagement of the fasteners. Another preferred side rail has directional hook fastener to prevent premature engagement of the fasteners.

RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 13/238,769, filed Sep. 21, 2011, which is a continuation ofU.S. patent application Ser. No. 12/879,211, filed Sep. 10, 2010, nowU.S. Pat. No. 8,033,591, which is a continuation of U.S. patentapplication Ser. No. 11/925,504 filed Oct. 26, 2007, now U.S. Pat. No.7,815,239, the disclosures of which are all hereby incorporated byreference.

FIELD OF THE INVENTION

Tonneau cover assemblies, particularly, Tonneau cover assemblies forroll-up covers including a flexible cover and an apparatus for attachingthe flexible cover to a cargo box of a pickup truck. The presentinvention further relates to tonneau cover assemblies having side railsthat are attached to sidewalls of the cargo box. The flexible covers caninclude hook and/or loop fasteners secured to each of the respectiveside rails.

DESCRIPTION OF THE RELATED ART

Numerous protective cover assemblies for preventing rain, debris andwind from damaging or disrupting the contents of a pickup truck bed arecurrently available. Generally, the covers are made of some sort offabric, often a fabric coated with a polymeric material, which isdetachably fastenable to a rigid frame so as to enclose and protect thepickup truck cargo box. The covering materials used are generallystretchable to the extent that once they are in a position to besecured, they are pulled taut and then attached to the frame by numerousmethods such as snaps, grommets, or multi-directional hook-and-loopfasteners and stretcher bars.

Typical protective cover assembly frames include a pair of elongatedside rails that are secured to the sidewalls of the cargo box. Various“low profile” side rails have been developed to achieve the desirablelook of a cover that does not extend significantly above the top of thesidewalls of the pickup truck. Known side rails that provide a lowprofile appearance often include a component of multi-directional hookstrip fastener secured on the side rail, typically within a horizontalchannel that does not significantly extend above the top of the sidewall(see, e.g., U.S. Pat. Nos. 4,036,521 and 4,991,640 and 6,752,449).Inclined side rails having a component of multi-directional hook andloop fastener are also taught (see, e.g., U.S. Patent Appln. Pub. No.2004/0212212 A1).

The present invention provides improvements which address limitationsassociated with the prior art.

SUMMARY

One preferred embodiment relates to an elongated side rail forattachment to a sidewall of a pickup truck cargo box as a portion of atonneau cover assembly. This tonneau cover assembly preferably includesa flexible cover that can be operatively secured to two side rails, eachof which are secured to one of the respective sidewalls of the pickuptruck cargo box, one opposite the other, to form elements of a securingframe to which the flexible cover is secured when the tonneau coverassembly is closed or fully engaged. Each elongated side rail of thisembodiment preferably includes a securing portion that can beoperatively connected to the sidewall and an inclined portion extendingfrom the securing portion, the inclined portion having a first edge anda second edge. The preferred side rail further includes a connectingmember that extends downwardly away from the inclined portion from aposition located between the first and second edges and a longitudinalportion extending away from the connecting member opposite the inclinedportion. The side rails are preferably aluminum extrusions. In designingthe cross-sectional shape of the preferred side rails, the presentinventors discovered that, by interconnecting the longitudinal member tothe center of an underside of the inclined portion with the connectingmember placed between the edges of the inclined portions, considerablesavings of materials and cost for materials can be derived fromdiminishing the thickness of the inclined portion that extends beyondthe connecting member, because greater thickness is not required tosupport the longitudinal portion.

Preferably, to secure the flexible cover to each of these respectiveside rails, a first component of hook and loop fastener (first fastenercomponent) is secured to the inclined portion of each side. The firstfastener component reciprocates a second component of hook and loopfastener (second fastener component) that is located on the bottoms ofeach side of the flexible cover. In preferred embodiments, the tonneaucover assembly can have two securing plates attached to opposite ends ofthe flexible cover. The front securing plate is secured to the siderails at a forward end of the cargo box and the rear securing plate issecured to the side rails at the rear end of the cargo box to form thesecuring frame in a manner similar to that disclosed in U.S. Pat. Nos.5,076,338 and 6,543,835, each of which is incorporated herein byreference. During development of embodiments having low profile siderails, the present inventors, discovered that, when the preferred coveris secured to the forward end and drawn over the top of the side rails,so that the rear securing plate can be engaged with securing plateengagement members on each of the respective side rails, the secondfastener components on each of the bottom of each of the respectivesides of the flexible cover might prematurely engage with the respectivefirst fastener components on the respective inclined portions. Thispremature engagement of the respective fastener components wasdiscovered to diminish the ability of the sides of the flexible cover toslide along the respective side rails to allow the flexible cover tobecome tautly drawn over the securing frame when the rear securing plateis engaged with respective side rails and pivoted into the closedposition. It is not believed that this problem often arises when theangle between the engagement surface of the securing portion and theupper surface of the inclined portion is greater than 135°. It wasdiscovered, however, that when this angle is 135° or less, prematureengagement is likely to occur. To address this problem, the presentinventors have discovered a number of ways to either prevent prematureengagement or diminish the degree to which premature engagementdiminishes the ability of the sides of the flexible cover to slide alongthe respective side rails when the rear securing plate is pulling theflexible cover over the securing frame so that it can be tautly secured.It will be appreciated that sales of tonneau cover assemblies will bediminished if a cover prematurely engages the fastener component on theside rails making it more difficult to close the cover assembly. Thispremature engagement diminishes the ability of the sides of the cover toeasily slide rearward when the rear securing plate is being fullyengaged, forcing the sides to pull the prematurely engaged secondfastener component away from the first fastener component in ahorizontal plane, which can damage both of the fastener components whenpulled away in this way. It will be appreciated that the appearance of aflexible cover that is tautly drawn over a cargo box is desirable toconsumers and that a tautly drawn flexible cover diminishes thepossibility that rain water or snow will pool in low spots over themiddle of the cargo box, which is also believed to be undesirable.

Preferably, each side rail of this and several other embodiments furtherincludes a channel defined by retaining portions on each respective edgeof the inclined portion. The side rail can have a low profile such thatthe flexible cover does not significantly extend above the sidewalls. Inalternate low profile embodiments, the inclined portion preferablyextends from the securing portion, relative to the engaging surface ofthe securing portion that engages the sidewall, at an angle ranging frombetween about 90° to about 135°. In certain alternate embodiments, theinclined portion has a ridge extending generally along the length of theside rail proximate an edge of the inclined portion closest to, or mostproximate to, a center of the flexible cover, such that when theflexible cover is pulled over the cargo box, the longitudinal sides ofthe cover ride along the ridges such that the respective second fastenercomponents do not prematurely engage the corresponding first fastenercomponents on the respective side rails. This permits the flexible coverto be drawn tautly over the securing frame when the rear securing plateis placed into a closed position. Once the cover is secured tautly overthe securing frame, the lateral sides of the cover can be pressed downon the respective side rails, so that the respective second fastenercomponent can engage the first fastener component on the respective siderails.

Many flexible cover roll-up tonneau covers have been sold in the UnitedStates and elsewhere. Examples include the tonneau covers disclosed inU.S. Pat. Nos. 5,076,338 and 6,543,835 referenced above. As the presentembodiment incorporates design changes made to the side rails fortonneau cover assemblies such as these tonneau covers, particularly tomake tonneau covers having a lower profile, the angle of incline of thesurface to which the first fastening component is attached has, in somecases, increased with respect to the engagement surface of the securingportion so that the plane in which the first fastener component resideshas moved closer and closer to being horizontal. This allows the secondfastener component to engage the first fastener component when theflexible cover is first drawn over the securing frame, but before thesecuring plate at the rear of the pickup truck is fully engaged with therespective securing plate engagement members associated with therespective side rails. This premature engagement of the respectivefastener components can lead to damage of the hook and loop structuresare pulled horizontally with respect to one another when the securingplate at the rear of the truck pulls the flexible cover tightly over thesecuring frame as it is pivoted into full engagement with the siderails, and the respective sides of the flexible cover often need to bedisengaged and than reengaged with the respective side rails so that thesides can be aligned with the rest of the flexible cover to evenlysecure the cover over the securing frame. Premature engagement of thefirst and second fastener components typically occurs when the lateralsides of the cover, including the respective second fastener components,flop down onto the side rails and the inclined surface to which thefirst fastener component is attached before the flexible cover is drawntightly over the securing frame so that it is stretched tautly over theframe. In the older covers, that did not have particularly low profiles,this was not a problem because the height of incline prevented therespective sides of the flexible covers from flopping down on therespectively first fastener components, because the incline of the firstfastener was greater and the lateral sides of the flexible coversincluded a stiffener portion in which the flexible cover material wasfolded over to create a greater stiffness at the edges of the respectivesides. This is still generally the case, but the lower angle of incline,which can be anywhere from 45° to less, even approaching zero withrespect to a horizontal plane, has reduced the effectiveness of thisstiffened portion. In certain preferred embodiments, however, the siderail will include a ridge. The ridge supports the stiffened lateral sideof the flexible cover, to which the second fastening component isattached, so that it is largely prevented from flopping down on areceiving surface of the side rail, where the first fastener componentis attached. In this way, the ridge largely prevents the second fastenercomponent from prematurely engaging the first fastener component andlargely diminishes any difficulty a tonneau cover owner might havedrawing the flexible cover tautly over the securing frame on the cargobox.

Alternate embodiments of the present invention address this potentialproblem in further ways. It will be appreciated that a ridge need not becontinuous. A discontinuous or intermittent ridge will also effectivelysupport the stiffened sides of the flexible cover, largely preventingthe premature engagement. Similarly, the ridge need not be a part of theedge of the inclined portion, but can alternately be a part of a firstfastener strip, so long as the fastener strip is inserted into thechannel so that the ridge on the edge of the fastener strip is locatedon the side of the respective inclined portions proximate the center ofthe center of the cargo box. This ridge can also be discontinuous. Othermechanisms for providing a ridge or an intermittent ridge on the side ofthe incline portion proximate the center of the cargo box, such as aseparate channel insert designed to reside in the channel with the firstfastener component are also contemplated.

The inventors, after becoming aware of the premature engagement problemsthat occurred during development of new low profile tonneau covershaving hook and loop fastener components, discovered that this prematureengagement problem, which limits a user's ability to effectively fullyengage the rear securing plate so that the flexible cover can be tautlysecured over the cargo box when the front securing plate is alreadyengaged, also can be addressed using a newly developed directional hookfastener strip on the inclined portion and loop fastener on theunderside of stiffened edge of the sides of the flexible cover. Theinventors discovered that the directional hook fastener, which has neverbeen used before on a truck cover side rail, surprisingly permits thehook fastener on flexible cover to be drawn over the directional hookwhen the rear securing plate is engaged with the respective side rails.So, while there may be some premature engagement of the hook fastenercomponent on the underside of the respective stiffened edges of therespective sides of the flexible cover and the directional hook fastenercomponent on the inclined portion of the side rail, when the flexiblecover is drawn toward the rear of the cargo box as the rear securingplate is engaged, the flexible cover can be drawn tautly over the cargobox rather easily because the directional hook component releases theloop component when it is pulled horizontally with respect to thedirectional hook, allowing the loop to slide over the directional hookswithout causing damage to the loop or the directional hook structures,so long as the directional hooks are oriented in the direction of therear of the cargo box.

Both the ridge and the directional hook component on the incline portionof the side rail allow the flexible cover to have “slidable” engagementfasteners because each system permits the lateral sides of the flexiblecover to slide over the side rail as the cover is drawn tautly over thecargo box during the engagement process.

It will also be appreciated from a review of the drawings that theinclined portion of the present side rails need not necessarily beinclined, but may instead be “flat” in which case the surface of theinclined portion will be oriented at a 90° angle with respect to theengagement surface of the securing portion as shown in FIGS. 6 and 7.

Another preferred embodiment of the present invention relates to anelongated side rail for attachment to a sidewall of a pickup truck cargobox having a front and a tailgate, the elongated side rail being aportion of a tonneau cover assembly. The elongated side rail includes asecuring portion that can be secured to the sidewall. The elongated siderail further includes a fastener support member interconnected to thesecuring portion, the fastener support member including a receivingsurface having first and second edges. The first edge is closest to thecargo box when the elongated side rail is operatively secured to thesidewall. The elongated side rail also includes a component of stripfastening material that is secured on the receiving surface between thefirst and second edges and has a height. The preferred elongated siderail includes a ridge located proximate the first edge of the receivingsurface. The ridge has a height higher than the height of the fasteningstrip and extending above the second edge such that the ridge generallyprevents premature engagement of the components of strip fasteningmaterial when the flexible cover is being drawn over the cargo box.

In alternate embodiments of the present invention, the ridge can havenumerous configurations. The ridge can be a continuous raised portionextending generally along the receiving surface or the ridge can be aplurality of raised portions. In addition, the ridge can be locatedalong the entire length of the side rail or, alternatively, can extendalong only a part or parts of the length of the side rail.

Yet another preferred embodiment of the present invention relates to anelongated side rail for attachment to a sidewall of a pickup truck cargobox as a portion of a tonneau cover assembly having a flexible coverthat can be secured over the cargo box. The preferred elongated siderail includes a securing portion that can be secured to the sidewall anda fastener support member interconnected to the securing portion. Thefastener support member includes a receiving surface having a first edgeand a second edge and an elongated strip component of directional hookfastener located between the first and second edges. The preferredelongated strip component of directional hook fastener is of the typehaving a plurality hooks that generally all face the same direction suchthat the hook fastener will engage corresponding loop fastener on theflexible cover in only one direction.

The use of directional hook fastener is particularly useful inembodiments where the receiving surface is generally horizontal (“lowprofile” tonneau covers). Generally, horizontal receiving surfaceshaving multidirectional hook fastener often prematurely engage thecorresponding loop fastener of the cover as the cover is being pulledover the cargo box. Premature engagement damages the fastener and makesit difficult to attach and properly tension the cover. Directional hookfastener, when secured to the receiving surface such that the hooks facethe tailgate, will allow the cover to slide in the direction of thetailgate but without subjecting the respective fastener components todamage can be purposefully engaged with the loop fastener by simplypressing the loop fastener down on to the directional hook fastener.

These and various other advantages and features of novelty whichcharacterize the present invention are pointed out with particularity inthe claims annexed hereto and forming a part hereof. However, for abetter understanding of the invention, its advantages and objectsobtained by its use, reference should be made to the drawings which forma further part hereof, and to the accompanying descriptive matter, inwhich there is illustrated and described a preferred embodiment of thepresent invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description of the invention can be betterunderstood with reference to the accompanying drawings, wherein

FIG. 1 is an end view of a tonneau cover apparatus of the presentinvention installed over a cargo box of a pickup truck (shown partially,in phantom);

FIG. 2 is a partial, perspective view of the tonneau cover apparatus ofFIG. 1, wherein the tonneau cover apparatus includes a flexible coverthat has been partially rolled-up to expose a portion of a side rail;

FIG. 3A is a cross-sectional view of the side rail of the tonneau coverapparatus of FIG. 2 as viewed along line 3A-3A of FIG. 2; the side railis attached to a sidewall of the cargo box (the flexible cover and otherelements shown in FIG. 2 have been omitted for clarity);

FIG. 3B is a partial, cross sectional view of an alternate embodiment ofa side rail, similar to that of FIG. 3B, but illustrating an alternateridge configuration in which the side rail does not have a ridge and theridge is part of a first fastener component within a channel in the siderail;

FIG. 4 is a cross-sectional view of the side rail of FIGS. 1-2 as viewedalong line 3A-3A of FIG. 2 showing a first covered position (in phantom)in which the flexible cover is draped over the cargo box and the ridgesupports the stiffened portions of the flexible cover so that the secondfastener component does not prematurely engage the first fastenercomponent; and a second covered position in which the second fastenercomponent on the flexible cover is engaged with the first fastenercomponent on the side rail;

FIG. 5A is an cross-sectional view similar to that of FIG. 3A of anotherembodiment of a side rail;

FIG. 5B is a partial, cross-sectional view similar to that of FIGS. 3Band 5A of another embodiment of a side rail;

FIG. 6 is an cross-sectional view similar to that of FIGS. 3A and 5A ofan additional embodiment of a side rail;

FIG. 7 is a partial, cross-sectional view similar to that of FIG. 5B ofyet another embodiment of a side rail in which fastener strips are shownschematically in two different positions;

FIG. 8A is a partial, cross-sectional view of the ridge of FIG. 6 asviewed along line 8A-8A of FIG. 6;

FIG. 8B is a partial, cross-sectional view of an alternate ridge similarto that of FIG. 8A, but showing a discontinuous or intermittent ridge;

FIG. 9 is a partial, cross-sectional view of a rear securing plate ofthe tonneau cover apparatus as viewed along line 9-9 of FIG. 1, thesecuring plate having an open position (shown in phantom) and a securedor fully engaged position in which the securing plate is engaged withengagement members associated with each of the respective side rails;

FIG. 10 is a perspective view of the engagement member of FIG. 9;

FIG. 11 is a cross-sectional view of the engagement member of FIG. 10 asviewed along line 11-11 of FIG. 10;

FIG. 12 is an cross-sectional view similar to that of FIG. 3 of anotherembodiment of a side rail, the side rail having directional hookfastener component; and

FIG. 13 is a partial, cross-sectional view of the directional hookfastener component of FIG. 12 as viewed along line 13-13 of FIG. 12.

FIG. 14A is a schematic view of the directional hook fastener componentshown FIG. 12 as seen from a line similar to line 13-13, but showing aloop fastener component on the flexible cover sliding toward the rear ofthe cargo box as the securing plate is drawing the cover toward the rearduring a process of fully engaging the securing frame; and

FIG. 14B is a view similar to that of FIG. 14A, except that the securingplate is fully engaged and the loop fastener component is engaged withthe directional hook fastener component.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, particularly FIGS. 1-2, there isillustrated a preferred embodiment of a tonneau cover apparatus 1attached to a pickup truck 2. The pickup truck 2 has a cargo box 4 atleast partially defined by two opposing sidewalls 6, a tailgate 12 and afront wall 14. The tonneau cover apparatus 1 includes a flexible cover18. The flexible cover 18 includes opposing longitudinal sides 20 andopposing lateral sides 21 or ends 21. FIG. 1 illustrates the flexiblecover 18 drawn tautly draped over the cargo box 4 of the pickup truck 2when the tonneau cover apparatus 1 is in a closed position. FIG. 2partially illustrates a tonneau cover apparatus 1 in an open positionwhen the flexible cover 18 is partially rolled up. Referring now also toFIGS. 3A and 4; each outer sidewall 6 has an inner surface 8 and a topsurface 10. The flexible cover 18 is preferably constructed of somewhatresilient fabric material which is laminated to a polyester sheet togive it strength, flexibility, and water resistance.

Referring now also to FIGS. 9-11, the respective lateral sides 21 of theflexible cover 18 are preferably attached to respective securing plates70, 71. The rear securing plate 70 is shown in FIG. 9 and the frontsecuring plate 71 is shown in FIG. 2. The flexible cover 18 can besecured to a side rail assembly 30 that includes two side rails 32 thatare secured to the respective sidewalls 6 of the pickup truck 2 bysecuring the respective securing plates 70, 71 to the side rails 32 toform a securing frame (not shown) consisting of the two opposing siderails 32, to which the respective securing plates 70, 71 are attachedproximate respective ends of the cargo box 4, when the tonneau coverapparatus 1 is closed. The inclined position 38 includes a receivingsurface 46 that resides generally in an inclined plane that isconsistent with the receiving surface. The connecting member 40 extendsdownwardly away from the inclined portion 38 at an angle of about 90°relative to the inclined plane.

Each of the preferred side rails 32, as illustrated in FIGS. 2-3A,includes a securing portion 34 having an engaging surface 35 that ispreferably secured to an inner surface 8 of a respective sidewall 6with, for example, a series of clamps 16 positioned along the side rail32. Preferably, in embodiments where the securing portion 34 is securedto the respective sidewall 6 with clamps 16, the securing portion 34 hasa grooved surface 36 to enhance the grip of the clamp 16.

Referring now particularly to FIG. 3A, showing the preferred side rail32 of FIGS. 2 and 9 in lateral cross-section, the side rail 32 includesan inclined portion 38 that has a thick portion 39 a and a thin portion39 b separated by a connecting member 40 that extends generallyperpendicularly away from the inclined portion 38 to a longitudinalportion 52. The greater thickness T1 of the thick portion 39 a givesside wall 32 greater strength between the securing portion 34 and theconnecting member 40, where strength is most needed to support theweight of the flexible cover 18, the securing plates 70, 71 and supportmembers 28, which essentially rest on the longitudinal portion 52 whenthe tonneau cover apparatus 1 is closed or when it is partially openedand the flexible cover 18 is partially rolled up. By limiting thedistance between the securing portion 34 and the connecting member 40,the inventors isolated stress from supporting the weight of these partsof the apparatus to the thick portion 39 a of the inclined portion 38and the areas that are interconnected to the securing portion 34 and theconnecting member 40. For this reason, there is little need for the thinportion 39 b, which extends beyond the interconnection with theconnecting member 40, to have a thickness that is as great as thethickness of the thick portion 39 a. For that reason, the thickness T2of the thin portion 39 b is thinner than the thickness T1 of the thickportion 39 a, preferably about 10% thinner, more preferably about 25%thinner, more preferably about 40% thinner. In the most preferredembodiment, T1 is 0.110 inches and T2 is 0.062 inches.

In certain embodiments, the inclined portion 38 has a receiving surface46 and proximal and distal retaining portions 54, 56, that cooperate toform a channel 58. Within the channel 58 or, alternatively, simply onthe receiving surface 46, a strip of hook and/or loop fastening material64 can be secured that reciprocates or corresponds to a strip of hookand/or loop fastening material 22 on the longitudinal sides of theflexible cover 18 for securing the flexible cover 18 over the cargo box4. As shown, the components of strip fastener 22, 64 can bemulti-directional hook fasteners and loop fasteners, respectively. Inpreferred embodiments, the loop component of strip fastener is securedto a stiffened portion 26 of the flexible cover 18 where a edge of thecover has been folded under so that the stiffened portion 26 has adouble thickness of the material use to make the flexible cover 18.

In “low profile” embodiments, when the inclined portion 38 or receivingsurface 46 extends from the securing portion 34 at an angle A1 about135° or less, relative to the engaging surface 35 of the securingportion 34, the side rail 32 will preferably include a ridge 60extending upwardly and along the distal retaining portion 56 inpreferred embodiments. In preferred embodiments the angle A1 will befrom about 135° to about 90°, preferably from about 135° to about 100°.In the embodiment show in FIG. 3, the angle A1 is 112°. The ridge 60supports the longitudinal sides 20 of the flexible cover 18 above thecomponent of strip fastener 64 on the side rail 32 so that the cover 18can be draped over the cargo box 4 without having the strip fastener 22on the stiffened portion 26 of the flexible cover 18 flop down on thestrip fastener 34 associated with the respective side rail 32, such thatthe respective fastener components 22, 64 prematurely engage.

As shown in phantom in FIG. 4, the ridge 60 will provide support for thestiffened portion 26 of the longitudinal side 20 of the flexible cover18 to keep it above the fastener component 64 on the side rail 32, whenthe flexible cover 18 is first draped over the respective side rails 32in a process of closing the tonneau cover apparatus 1. As the flexiblecover 18 is drawn more tightly over the cargo box 4 and the rearsecuring plate 70 is fully engaged with securing plate engagementmembers 86 on each of the opposing side rails 32, the outer part of thestiffened portion, to which the loop fastener component 22 is attached,will remain separated from the hook fastener component 64 until the userpresses down on the outer portion 27 of the stiffened portion 26 enoughto engage the loop fastener component 22 with the hook fastenercomponent 64 as shown in FIG. 4. Without this downward force on thestiffened portion 26, the loop fastener component 22 would notordinarily become easily engaged with the hook fastener component 64,because the ridge 60 provides a sufficient obstacle to keep the twofastener components 22, 64 separated.

Premature engagement of the components of strip fastener 22, 64 oftenresults in torn or damaged fastener components, while also making itdifficult to properly position and tension the flexible cover 18 overthe cargo box 4. The ridge 60 can be used in conjunction with theretaining portions 54, 56 to secure the first component of stripfastener 64 or can be used in embodiments without retaining portions 54where the first component of strip fastener 64 is secured on thereceiving surface 46 with other methods such as adhesives, rivets or thelike (see e.g. FIG. 12). It will be appreciated that the channel 58 willnot be necessary if an alternate component of hook and/or loop fastener(not shown) is secured to the receiving surface 46 with an adhesive orwith pop rivets or the like, and that the retaining portions will not berequired either. In this situation an alternate distal retaining portioncould simply include a ridge (not shown) to support the sides 20 of theflexible cover 18 to minimize premature engagement.

It will be appreciated that the side rails do not have to have a channel58 or a ridge 60, but that these aspects of the present side rails aredesirable is certain preferred embodiments such as the one shown inFIGS. 3A and 4. The fastener strip 64 preferably includesmulti-directional hooks 64 a extending from a fabric based stripfastening material 64 b that is secured by a polymeric adhesive material65 to a plastic slat 68 that is engaged within the channel 58.

In FIG. 4, a support member or bow 28 is shown that supports theflexible cover 18. There is generally a plurality of support members 28supporting the flexible cover 18 in preferred tonneau cover assemblies.The support members 28 traverse the space between the opposing siderails 32 secured to opposing side walls 6 of the cargo box 4. Inpreferred embodiments, the support members 28 are attached to theflexible cover 18 by securing a first strip of hook and/or loop fastenermaterial 24 to an underside of each side 20 or of the flexible cover 18,so that a second reciprocating hook and/or loop fastening strip 29,attached to each end of the support member 28, will be sufficientlyengagable by the first strip 24 to disengagably secure each end of thesupport member 28 to the flexible cover 18.

The lateral cross-section of yet another embodiment of a side rail 132is illustrated in FIG. 3B. In this embodiment, the side rail 132includes a fastening component 164 including a fabric strip fasteningmaterial 164 b, including multi-directional hook components 164 asecured to a slat 168. The slat 168 includes a ridge 162. This fasteningcomponent 164 does not require a ridge on the distal retaining portion156, because the slat 168 provides the ridge 162, which can support thestiffened portion 26 of the flexible cover 18 in the same manner as thestiffened portion 26 is supported by the ridge 60 shown in FIG. 4.Preferably, the slat 168 is made of an extrudable material so that theridge 162 can be formed by extruding the slat 168 to include the ridge162. Once the slat 168 is formed, the respective fabric strip fasteningmaterial 164 b can be secured to the slat 168. The slat 168 ispreferably arranged and configured such that the slat 168 can slide intoand be retained within a channel 158 that is at least partially formedby two retaining portions 154, 156 and a receiving surface 146 of theinclined portion 138. Similar to the embodiment of FIG. 3A, the inclinedportion 142 is interconnected to a securing portion 134 having a groovedsurface 136 that can be clamped to the sidewall 6 of a pickup truck 2.In addition, the preferred inclined portion has a connecting member 140extending downwardly from the inclined portion 142 in between first andsecond edges 148, 150 of the receiving surface 146 to save on materialcosts as discussed above.

FIG. 4 illustrates the side rail 32 of FIG. 3A in operation. In use, theflexible cover 18 is draped from one lateral side 21 of the cargo box 4to the other. As the flexible cover 18 is being pulled over the cargobox 4, the ridge 60 is arranged and configured to support the firstcomponent of strip fastening material 22 above the second component ofstrip fastening material 64 on the side rail 32 such that the twocomponents of strip fastening material 22, 64 do not engage while theflexible cover 18 is being draped over the cargo box 4 (as shown inphantom). Also shown in FIG. 4 is a support bar 28. The preferredflexible cover 18 includes a plurality of support bars 28 that extendfrom one longitudinal side 20 of the flexible cover 18 to the otherlongitudinal side 20. As the flexible cover 18 is unrolled or drapedover the cargo box 4, the support members 28 are supported on thelongitudinal portions 52 of each of the opposing side rail 32 such thatthe flexible cover 18 is further supported over the cargo box 4.Preferably, each respective end of each support member 28 includes aremovable fastener 29 that corresponds to a removable fastener 24 on theflexible cover 18. The removable fastener 29 located on the supportmember 28 is preferably a loop fastener that encircles the supportmember 28 such that any vibration of the side rail 32 is dampened by theremovable fastener 29. When the vibration is dampened, the supportmembers 28 have less of a tendency to bounce on the longitudinalportions 52 when the pickup truck 2 is being driven, which reduces noiseand wear on the flexible cover 18. Once the flexible cover 18 is fullypositioned over the cargo box 4, a user can run their hand along the topof the flexible cover 18 along the component of strip fastening material22 of the cover 18 to engage the component of strip fastening material22 with the second component of strip fastening material 64 on the siderail 32.

Referring now also to FIG. 5A, an alternate embodiment of a side railassembly 230 is illustrated. In this embodiment, the side rail assembly230 includes a side rail 232 having a securing portion 234 that can beoperatively connected to the sidewall 6 of the pickup truck 2 withself-tapping screws 17 or the like. Extending from the securing portion234 is a fastener support member 244 having a receiving surface 246 onwhich a component of strip fastener 264 can be secured. In embodimentswhere the component of strip fastener 264 is multi-directional hookfastener such as that shown in FIG. 5A, the side rail 232 preferablyincludes a ridge 260 extending upwardly from the receiving surface 246and along the distal retaining portion 256 of the side rail 232 toprevent premature engagement of the components of strip fastener 264, 22when the flexible cover 18 is being secured over the cargo box 4 (seealso, FIG. 2). In this embodiment, the fastener support member 244includes a pair of retaining portions 254, 256 that cooperate with thereceiving surface 246 to form a channel 258 in which the first componentof strip fastener 264 is secured. In other alternative embodiments, thefirst component of strip fastener 264 can be directional hook fasteneras will be described below. The use of directional hook fastenerminimizes the negative consequences of premature engagement of thecomponents of strip fastener.

Referring now also to FIG. 5B side rail assembly 330 having a side rail332 similar to that of FIG. 5A is illustrated. In this embodiment,however, a component of strip fastener 364 is illustrated, that includesa slat 368 including a ridge 362. Since the ridge 362 is provided by thecomponent of strip fastener 364 that resides in the channel 58, there isno need for a ridge on the distal retaining portion 356.

FIGS. 6-7 illustrate additional embodiments of side rails assemblies430, 530. In these embodiments, a securing portion 434, 534 of therespective side rails 432, 532 can be operatively connected to therespective sidewall 6 with at least one clamp 16 in a manner shown anddescribed in relation to FIG. 3A. Extending from the securing portion434, 534 is a fastener support member 444, 544 having a receivingsurface 446, 546. Similar to the embodiment of FIG. 5A, the fastenersupport member 444, 544 includes retaining portions 454, 456, and 554,556, wherein the distal retaining portions 456, 556 include a ridge 460,560. As previously discussed, the ridge 460, 560 prevents prematureengagement of a component of strip fastener that is preferably securedproximate the receiving surface 446, 546. The embodiment of FIG. 7further includes upper retaining lip 557 located immediately below theridge 560. The upper retaining lip 557 provides an alternate channel 559to retain the strip fastener component 564 shown only schematically inphantom residing alternatively in each of the lower channel 558 and theupper channel 559. In either case, the raise ridge 560 will minimize anypotential premature engagement of the respective strip fastenercomponents. When the first component of strip fastener 564 resides inthe upper channel 559, the strip fastener component 564 will only reston the receiving surface 546 at the side near the proximal retainingportion 554 and will be raised and reside at angle to the receivingsurface 546 near the distal retaining portion 556 that is positionedclosest to the center of the cargo box 4. The embodiments of FIGS. 6-7further include a connecting member 440, 540 that interconnects thefastener support member 444, 544 to a longitudinal portion 452 on whichsupport members 28 of the flexible cover 18 are supported (see also,FIG. 4). As previously discussed above, the ridge 460, 560 can besubstituted or enhanced by additionally using directional hook fastenerinstead of multi-directional hook fastener.

Referring now also to FIG. 8A, a partial side view of the ridge 460 ofFIG. 6 is shown. The ridge 460, in this embodiment, has a continuousraised portion 461 that extends the general length of the side rail 432.The ridge 460 of the present invention prevents premature engagement ofthe respective components of strip fastener (not shown), wherein onecomponent is attached to the receiving surface 446 and the othercomponent of strip fastener is attached to the underside of the flexiblecover 18 as previously discussed. In preferred embodiments, the fastenersupport member 444, 544 includes retaining portions 454, 554 and 456,556, respectively that, in combination with the receiving surface 446,546 define a channel 458, 558 in which a first component of stripfastener can be secured (not shown). In alternate embodiments, thecomponent of strip fastener can be secured with rivets, adhesive or thelike. The preferred ridge 460 has a height H1 that is taller than theheight H3 of the proximal retaining portion 456 or a lip 456 a of thedistal retaining portion 456, of which the ridge 460 is a part. This isso that the flexible cover 18 will ride along the ridge 460, and notanother element of the side rail 432, when being draped over the cargobox 4 (see also, FIG. 4). Although the side rail 432 of FIG. 6 includesa generally horizontal fastener support member 444, it will beappreciated that providing a ridge having a height H1 greater than anyelement of the fastener support member for all side rails of similarembodiments is preferred.

FIG. 8B illustrates one of many alternate ridge configurations of thepresent invention similar to that shown in FIG. 8A. In this embodiment,the ridge 460′ includes a plurality of raised portions 461′ positionedalong the length of the side rail 432′. In further alternate embodiments(not shown), the ridge can include one or more raised portions extendingvarious lengths of the side rail. It will be obvious to one of ordinaryskill in the art that, in light of this disclosure, there are many ridgeconfigurations can be used that will result in substantially similarfunction.

FIG. 9 illustrates a rear securing plate 70 that is used to secure therear end or lateral side 21 of the flexible cover 18 to the cargo box 4.The securing plate 70 includes a distal edge 72 having a first channel76, in which a portion of the lateral side 21 of the flexible cover 18is secured. The first channel 76 is sized and configured such that oneof the lateral sides 21 of the flexible cover 18 can be force fit andretained around a cord 74 within the first channel 76 with a screw 90.The securing plate 70 preferably also includes a second channel 77,which is sized to slidingly receive a locking member (not shown). Thelocking member can be of the type disclosed in U.S. Pat. No. 6,534,835,the disclosure of which has been incorporated herein by reference. Inpreferred embodiments, the second channel 77 is generally T-shaped andincludes opposing sidewalls 78, an upper wall 80 and opposing flanges82. When the securing plate 70 is rotated or pivoted into a closedposition against a pair of securing plate engagement members 86 on therespective opposing sidewalls 32, only one of which is shown, a peak orcrest 84 of the securing plate 70 contacts a pivot point 88 of theengagement member or strike 86.

The preferred securing plate strike or engagement member 86 isillustrated in FIGS. 9-11. The preferred tonneau cover assembly 1includes two securing plate engagement members 86, one attached to eachrespective side rail 32, preferably with an embedded threaded screw 87coupled with a reciprocating nut 89 or the like. Alternatively, a hole(not shown) could be created in the strike to receive a simple bolt (notshown) that could secure the strike to the side rail 32 (see also, FIG.2). Each securing plate engagement member 86 includes an engagement area92 having a contoured portion 94 and the pivot point 88. To secure theflexible cover 18 over the cargo box 4, when the front securing plate 71is already attached to the respective side rails 32, the rear securingplate 70 is inserted within the engagement area 92. The distal end 72 ofthe securing plate 70 is then pushed downward and the peak or crest 84will engage and then pivot against the pivot point 88 of the respectiveengagement member 86 until the securing plate 70 is in the closedposition shown in FIG. 9. The securing plate 70 preferably exerts atensile force upon the flexible cover 18 so that the flexible cover 18will stretch and remain taut over the cargo box 4. As the securing plate70 pivots with respect to the pivot point 88, it will be appreciatedthat the distal end 72 will pull the flexible cover toward the rear ofthe cargo box 4. As this process of closing the preferred tonneau coverapparatus 1 proceeds, the longitudinal sides 20 of flexible cover 18will be pulled backward over the ridges 60 of the side rails 32. Inalternate embodiments, other raised ridges 260, 460, 560, 460, 162provided either by the side rails 232, 432, 532, 432 or the plasticslats 168 support the sides 20 of the flexible cover 18 to minimizepremature engagement of the respective strip fastener components asdiscussed. The front securing plate 71 may be secured to the respectiveside rails 32 in a similar manner to that described for the rearsecuring plate 70 or in a manner similar to those systems described inU.S. Pat. Nos. 5,076,338 and 6,543,835, each of which has beenincorporated herein by reference.

FIGS. 12-14B illustrate another preferred side rail assembly 630. Theside rail assembly 630 includes a side rail 632 having a securingportion 634 that can secure the side rail 632 to the side wall 6. Theside rail 632 further includes an inclined portion 638 having areceiving surface 646 in which a strip of directional strip hookfastener 666 can be secured in place of traditional, multi-directionalhook fastener. Preferred embodiments include a connecting member 640extending downwardly away from the inclined portion 638 and isinterconnected to a longitudinal portion 652 that can provide supportfor a support bar (not shown) similar to that shown in FIG. 4.

The preferred directional hook fastener 666 includes a plurality ofhooks 667 that generally all face the same direction, unlike traditionalmulti-directional hook fastener that has a plurality of hooks facingmultiple directions such that the hooks will engage loop fastener fromall angles. In preferred embodiments, the directional fastener 666 ispositioned on the receiving surface 646 such that the hooks 667 areuniformly facing the tailgate 12 (see also, FIG. 1) when the side rail632 is operatively attached to the sidewall 6. In this position, thehooks 667 will generally not engage the component of hook and loopfastener 22, in this case loop fastener on the flexible cover 18, as theflexible cover 18 is being pulled over the cargo box 4 towards thetailgate 12 (see, in particular, FIG. 14A). Use of such directional hookfastener 666 reduces the wear and tear of the components of directionalhook fastener 666 and corresponding component of loop fastener 22 on theflexible cover 18. Although there is no ridge to minimize prematureengagement, the directional hooks 667, will release any prematurelyengaged loop structures 669, when the directional hooks 667 are orientedtoward the rear of the cargo box where the securing plate 70 will engagethe respective strikes 86 and pull the flexible cover 18 backward towardthe rear of the cargo box, thereby stretching the flexible cover 18 anddrawing it tautly over the cargo box 4 and the securing frame (notshown). As shown in FIG. 14A, when this occurs, the loop structures 669simply slide over the directional hooks 667. Once the flexible cover 18has been drawn over the cargo box 4, the user can simply run their handacross the top of the cover 18, proximate the components of hook andloop fastener 666, 22 to engage the loop fastener 22 with the hookfastener 666 as shown in FIG. 14B).

Directional hook fastener can be made, for example, in accordance withthe teachings of U.S. Pat. No. 7,172,008 (Vanbenschoten et al.); U.S.Pat. No.6,640,348 (Clune et al.); or U.S. Pat. No. 6,258,311 (Jens etal.) the disclosures of which are herby incorporated herein byreference.

It is to be understood, however, that even though numerouscharacteristics and advantages of the present invention have been setforth in the foregoing description, together with details of thestructure and function of the invention, the disclosure is illustrativeonly, and changes may be made in detail, especially in matters of shape,size and arrangement of parts within the principles of the invention tothe full extent indicated by the broad general meaning of the terms inwhich the appended claims are expressed.

What is claimed is:
 1. An elongated side rail for attachment to asidewall of a pickup truck cargo box as a portion of a tonneau coverassembly, the elongated side rail comprising: an inclined portion, theinclined portion having a first edge and a second edge; a connectingmember extending downwardly away from the inclined portion from aposition located between the first and second edges; and a longitudinalportion extending from the connecting member opposite the inclinedportion.
 2. The elongated side rail of claim 1, wherein the connectingmember extends downwardly at an angle of about 90° from the inclinedportion.
 3. The elongated side rail of claim 1, further comprising areceiving surface and a retaining portion on each respective edge of theinclined portion; wherein the retaining portions and the receivingsurface form a channel.
 4. The elongated side rail of claim 1, whereinthe inclined portion includes a thick portion and a thin portion, thethick portion having a first thickness and the thin portion having asecond thickness, the first thickness being greater than the secondthickness.
 5. The elongated side rail of claim 1, further comprising astrip of directional hook fastening material on the inclined portion. 6.The elongated side rail of claim 1, further comprising a strip offastening material on the inclined portion.
 7. The elongated side railof claim 6, wherein the inclined portion extends from the securingportion at an angle of from about 90° to about 135° relative to a planein which the engaging surface resides.
 8. An elongated side rail forattachment to a cargo box having a front and a tailgate, the elongatedside rail having a length and being a portion of a tonneau coverassembly, the elongated side rail comprising: a securing portion thatcan be secured to the cargo box; a fastener support memberinterconnected to the securing portion, the fastener support memberincluding a receiving surface having first and second edges; wherein thefirst edge is closest to a center of the cargo box when the elongatedside rail is operatively secured to the cargo box; a component offastening material having a height, the component of fastening materialbeing located on at least a portion of the receiving surface between thefirst and second edges; and a ridge located proximate the first edge ofthe receiving surface along at least a portion of the length of the siderail; the ridge having a height with respect to the receiving surfacehigher than the height of the fastening material, the ridge alsoextending above the second edge with respect to the receiving surface.9. The elongated side rail of claim 8, wherein, when the elongated siderail is attached to the cargo box, the fastener support member at leastpartially overlaps a sidewall of the cargo box.
 10. The elongated siderail of claim 8, further comprising a retaining member proximate eachrespective edge of the receiving surface, wherein a first height of theridge, with respect to the receiving surface, is higher than a height ofeach retaining member, with respect to the receiving surface.
 11. Theelongated side rail of claim 8, further comprising a connecting memberextending downwardly from the fastener support member; the elongatedside rail further comprising a longitudinal portion extending from theconnecting member in a direction that is generally perpendicular to anengaging surface of the securing portion.
 12. The elongated side rail ofclaim 8, wherein the ridge is a continuous raised portion.
 13. Theelongated side rail of claim 8, wherein the ridge is a plurality ofdiscontinuous raised portions.
 14. The elongated side rail of claim 8,wherein the receiving surface is perpendicular to an engaging surface ofthe securing portion.
 15. The elongated side rail of claim 8, whereinthe receiving surface is at an angle from about 90° to about 135° withrespect to an engaging surface of the securing portion.
 16. Theelongated side rail of claim 8, wherein the ridge is located on thereceiving surface.